PLC Technician

About the role

The incumbent provides advanced-level experience and skillsets in the Technical Department, focusing on the setup, programming, diagnostics, and troubleshooting of the plant's PLC and DCS control systems. This role ensures proper and efficient utilization of equipment, materials, and manpower while maximizing safety and reliability.

The PLC Technician 3 must be proficient in all aspects of mill control systems and instrumentation, assisting with the development and maintenance of control systems in the mill, powerhouse, and waste treatment. The role requires a high degree of technical aptitude, in-depth knowledge of manufacturing process controls, and the ability to troubleshoot and implement programming changes without oversight. The incumbent will also support the implementation of repair and upgrade projects, including planning, part specification, coordination, and supervision.

Responsibilities

• Setup, programming, diagnostics, and troubleshooting of PLC and DCS control systems.
• Maintain and improve equipment reliability, performance, and safety of personnel.
• Carry on-call phone duties and work weekends without assistance.
• Maintain well-organized and accurate records for equipment maintenance, process efficiency, government agency reports, permits, and material requisitions.
• Read, follow, and modify complex system drawings, including P&IDs, system loops, pneumatic/hydraulic schematics, electrical one-lines, and mass/energy balances.
• Assist with the management of all control systems in the mill, including maintenance of equipment RPM Program requirements, inspections, and SAR requirements.
• Troubleshoot and perform preventive maintenance, routine repairs, and overhauls without oversight.
• Collaborate on repair and upgrade projects, including planning, part specification, coordination, and supervision of in-house and third-party contractor resources.
• Stay abreast of new technologies and work with the engineering group to plan and implement new capital projects.
• Demonstrate a solid understanding of mill processes and how control systems impact them.
• Implement high-level concepts from customers within respective areas.

Electrical Experience

• Intermediate-level experience with wiring diagrams and schematics.
• Residential voltage systems (115/230 volt).
• Industrial voltage systems (3-phase 480/2400).
• Switchgear, circuit breakers, and fusing.
• Motor starters, heaters, and pilot circuitry.
• Pushbuttons, timers, and devices.
• VFD setup, operation, maintenance, and troubleshooting.

Instrumentation Experience

• Advanced-level experience with VDC and 4-20mA sensors and control devices for pressure, flow, temperature, position, voltage, current, strains, and consistency.
• Pneumatic control systems (valves/solenoids, positioners, pressures, flows, guides).
• Hydraulic control systems (valves/solenoids, positioners, pressures, flows, guides).
• Steam control systems (valves/solenoids, positioners, pressures, flows).
• Wiring diagrams and schematics.

Process Control Experience

• Advanced-level PLC setup, programming, and troubleshooting for Ladder Logic and Sequential Function Chart environments (Rockwell, Automation Direct).
• DCS/SCADA setup, programming, and troubleshooting in Function Block and Structured Text environments (Foxboro, Ignition).
• HMI setup, programming, and troubleshooting (Rockwell, Ignition, Foxboro).
• Networking of IP devices and understanding of protocols (Ethernet IP, TCP/IP, Modbus TCP).
• PID control loops and tuning.
• Experience with safety systems, including integration with legacy systems and upgrades to existing systems.

Safety

• Perform essential physical requirements for each position to be considered trained.
• Know, understand, and follow all applicable model programs, plant, department, and job-specific safety rules.
• Protect personal safety and the safety of others in the work area.
• Adhere to responsibilities within the plant’s emergency response program (first-aid, fire, evacuation, etc.).
• Actively participate in safety program components such as safety huddles, USG stretching program, BBS, Take 5’s, incident investigations, inspections, and submission of safety improvement ideas.
• Maintain proactive good housekeeping practices.
• Prevent damage to company equipment and materials; report damages, incidents, and injuries immediately.
• Complete LEAD training and applicable advanced training courses.
• Collaborate with direct supervisors, department leadership, and Safety Team representatives.

Continuous Improvement

• Understand the four categories of standard work and identify existing standards when supporting an area.
• Process Adherence: 5S, Visual Job Aids, Targets & Setpoints, Alignment Markers, Gauge Markers, Job Plans, Out of Compliance Response Plans, Operator Basic Care (OBC’s), and Preventative Maintenance (PM’s).
• Reference Bulletin Specifications, Engineering Drawings, and Manufacturing Manuals.
• Training: VWI’s, Job Breakdown Sheets, Training Videos, and Training Plans.
• Leader Gemba Walks, Coaching, and Reflection Meetings.
• Complete 5S LEAD training and support housekeeping initiatives using 5S principles: Sort, Set-in-Order, Shine, Standardize, and Sustain.

Requirements

• Advanced experience with industrial programming, instrumentation, and electrical trades.
• Advanced computer skills (Microsoft Office Suite, spreadsheets, data entry).
• Advanced competencies in communication, decision-making/problem-solving, energy, drive, ambition, job knowledge, leadership, managing conflict/negotiation, managing resources, and work quality.
• Advanced experience with manufacturing instrumentation systems and control panels, including adherence to NFPA codes.

Qualifications

• Licensed Electrician in the State of Michigan preferred.
• 3-5+ years of industrial controls and instrumentation/electrical experience.
• USG Safety Model Program, OSHA, FM Global, and Environmental compliance experience preferred.
• USG RPM program experience preferred.
• No significant performance/attendance infractions within the last 6 months.
• Ability to perform all tasks required in subsequent positions.
• Demonstrate assigned job description competency requirements within 12 months of start.

Benefits

• Two medical insurance options, vision, and dental coverage (employees generally pay 25% of the monthly premium cost).
• 401(k) Investment Plan with company match.
• Pension plan.
• Additional programs such as life insurance, accident insurance, legal insurance, and pet insurance.
• Quarterly (hourly) / Annual (salary) bonus potential based on performance metrics tied to safety, quality, and productivity.
• Paid time off and paid holidays.